Waste liquid solidification system and method

ABSTRACT

A waste liquid solidification system includes a chamber at least partially enclosing a volume, a liquid outlet positioned to spray a liquid into the volume, and a powder outlet adjacent the liquid outlet positioned to discharge a super-absorbent polymer powder into the volume. The liquid outlet and powder outlet are configured such that the liquid and the super-absorbent polymer powder undergo airborne mixing within the volume enclosed by the chamber to create a solid waste.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.14/695,784, filed Apr. 24, 2015, the entire contents of which areincorporated by reference herein.

BACKGROUND

The present invention relates to waste liquid solidification, and moreparticularly to a waste liquid solidification system that utilizessuper-absorbent polymer (SAP).

Some facilities produce liquid waste that cannot be pumped into localsewer systems due to municipal, local, state, and/or federalregulations. Typically, this kind of liquid waste is shipped to liquidwaste processing plants. However, this process can be cost inefficientin certain scenarios. On the other hand, disposal of solids is oftenmuch easier and more cost effective. In many cases, this is due at leastin part to the fact that properly-solidified solid waste can be lesslikely to leech into the ground and other environment of the disposedwaste—a result that can cause negative environmental effects.

SUMMARY

In one aspect, the invention provides a waste liquid solidificationsystem including a chamber at least partially enclosing a volume, aliquid outlet positioned to spray a liquid into the volume, and a powderoutlet adjacent the liquid outlet positioned to discharge asuper-absorbent polymer powder into the volume. The liquid outlet andpowder outlet are configured such that the liquid and thesuper-absorbent polymer powder undergo airborne mixing within the volumeenclosed by the chamber to create a solid waste.

In another aspect, the invention provides a method of solidifying wasteliquid. A stream of waste liquid and a stream of super-absorbent polymerpowder are simultaneously provided to a mixing chamber such thatparticles of the waste liquid stream and particles of thesuper-absorbent polymer powder stream are mixed while airborne tosolidify the waste liquid particles without any physical mixing oragitation. A quantity of solidified waste liquid is collected at abottom portion of the mixing chamber. The quantity of solidified wasteliquid is ejected from the mixing chamber.

Other aspects of the invention will become apparent by consideration ofthe detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of a waste liquid solidification device for usein a system according to one aspect of the invention.

FIG. 2 is a side view of a mixing chamber of the waste liquidsolidification device of FIG. 1, schematically illustrating a powder andliquid supplies, a pressure generator, and a filtration system coupledthereto.

FIG. 3 is an enlarged view of a portion of the mixing chamber shown inFIG. 2, illustrating liquid and powder outlets.

FIG. 4 is a cross-sectional top view of the mixing chamber as shown inFIG. 2, illustrating the liquid and powder outlets.

FIG. 5 is an enlarged view of a portion of the mixing chamber as shownin FIG. 2, illustrating the liquid and powder outlets in combinationwith an annular piston.

FIG. 6 is a cross-sectional top view of the mixing chamber as shown inFIG. 2, illustrating the liquid and powder outlets in combination withthe annular piston of FIG. 5.

DETAILED DESCRIPTION

Before embodiments of the invention are explained in detail, it is to beunderstood that the invention is not limited in its application to thedetails of construction and the arrangement of components set forth inthe following description or illustrated in the accompanying drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways.

The waste liquid solidification system described herein is used toconvert liquid waste into solid waste. This process can significantlyreduce costs associated with liquid waste shipping, processing, and/ordisposal. Solid waste may include rigid solid material as well assemi-solid (i.e., gelatinous) material. The waste liquid solidificationsystem utilizes a super-absorbent polymer (SAP) in the form of a finepowder that absorbs liquid waste to create a solid waste. SAP caninstead be found in other forms such as beads and crystals, and in someembodiments can be resiliently compressible. The composition of the SAPpowder may be matched to the particular type of liquid waste beinghandled and may be selected based on one or more desirable properties ofthe final solid waste. The SAP powder may absorb liquid waste bychemical means, physical means, or a combination thereof. The SAP powdermay absorb and retain approximately 500 lbs. of liquid waste for every20 lbs. of SAP powder used. The SAP powder may be a Waste SolidificationPolymer, such as sodium polyacrylate available from Therma-Tron-X, Inc.of Sturgeon Bay, Wis. under the product name PRO SHIELD M9910. The SAPpowder can be effective on both water-based waste and oil-based waste,by solidifying the liquid waste with coagulation chemicals, particularlyby congealing, gelling, or coalescing.

FIG. 1 illustrates a waste liquid solidification device 10 for use in awaste liquid solidification system according to one aspect of theinvention. The device 10 includes a mixing tank or chamber 14 held in anupright or vertical orientation with respect to the ground by aplurality of supporting legs 18 attached to the sides of the mixingchamber 14. The supporting legs 18 hold the mixing chamber 14 above theground in a spaced relationship such that solid waste may be evacuatedout of the bottom of the mixing chamber 14. The volume defined by themixing chamber 14 is configured to receive liquid waste and SAP powderfrom respective liquid and powder outlets 30, 34 positioned within themixing chamber 14 to create a batch of solid waste from a quantity ofliquid waste pumped from a liquid waste reservoir 35 to the mixingchamber 14. The mixing chamber 14 also incorporates a filtration systemto help regulate the internal pressure of the system and avoid ejectingthe SAP powder into the surrounding environment. The filtration systemcan include a filter housing 36 with one or more filtration elements 36Aor filtration media suitable for entrapping the particles of the SAPpowder so that the SAP powder is contained within the system and notreleased to the surrounding environment. The filter housing 36 caninclude a first inlet coupled to the mixing chamber 14 (e.g., via avalve and/or hose) and can further include a second inlet coupled to apowder reservoir or hopper 38 from which the SAP powder is pumped to themixing chamber 14. Alternately, or in addition, air or anotherpressurized gas source may flow from one or both of the powder hopper 38and the mixing chamber 14 through a cyclonic separator to separate thepowder from the gas stream and prevent the escape of the SAP powder.

The device 10 also includes an outlet valve 22 located on a lower orbottom end of the mixing chamber 14 that may cooperate with an ejectionsystem, to eject each batch of solid waste, once finished. The device 10may also include one or more access flanges 50 adjacent a lower side ofthe chamber 14 and located above the outlet valve 22 to provide accessto the internal volume of the chamber 14 for maintenance or cleaning. Insome constructions, the device 10, including the supporting legs 18, maystand approximately 15 feet tall at its highest point, with the mixingchamber 14 being approximately 1.5 feet to 2 feet in diameter. However,the size and/or shape of the device 10 and the features thereof (e.g.,the mixing chamber 14) may vary based on different applications andshould not be regarded as limiting. Further, while a vertically-orientedmixing chamber 14 may have particular benefits, such that gravityassists with evacuation of the solid waste, the orientation of thedevice (i.e., vertical, horizontal, etc.) may vary among particularapplications.

As illustrated in FIGS. 2-4, the mixing chamber 14 encloses a volume formixing liquid waste supplied by the pair of liquid outlets 30 with theSAP powder discharged from the powder outlet 34. The mixing chamber 14is lined with a smooth chemical-resistant (e.g., epoxy) coating oninternal sidewalls. The liquid outlets 30 and the powder outlet 34 arearranged in close proximity such that the SAP powder absorbs and retainsthe liquid waste particles in the air as both substances are dischargedfrom their respective outlets 30, 34. No additional mixing (e.g.,stirring, agitating, swirling, etc.) is carried out. In the illustratedembodiment, the powder outlet 34 is centered between and located justbelow the liquid outlets 30 (FIGS. 3 and 4), for example, about 6 inchesbelow the liquid outlets 30. The liquid outlets 30 may spray the liquidwaste in a particular pattern (e.g., conical, mist, etc.) to facilitatemixing. The SAP powder discharged from the powder outlets 34 is releasedin a fine mist or cloud of particles due to the fine nature of the SAPpowder when pumped with air. This arrangement facilitates the airbornemixing of the liquid waste particles and the SAP powder particles.Furthermore, the liquid outlets 30 may define overlapping spray patternsas schematically illustrated in FIG. 4 by respective groups of radiallines emanating from each of the liquid outlets 30. The overlappingspray patterns encompass the entire cross-section of the mixing chamber14 to contain the SAP powder below the level of the liquid spray. Insome constructions, each one of the liquid outlets 30 defines a spraypattern that encompasses the entire cross-section of the mixing chamber14. A nozzle may be provided at each of the liquid outlets 30 to definethe spray pattern. The nozzles may take a variety of different forms,and in some constructions, may be adjustable to vary the spray pattern.The solid waste created from the airborne mixing of the liquid waste andthe SAP powder collects in the lower half of the mixing chamber 14 untila batch is finished. The batch may be considered finished when apredetermined amount of solid waste is accumulated in the mixing chamber14. Various sensors (e.g., weight, height, etc.) may be used todetermine when a batch is finished and ready for evacuation.Alternatively, or in addition, the solidification system supplies only apredetermined amount of SAP powder and a predetermined amount of liquidwaste to the device 10 per batch based on the capacity of the mixingchamber 14 or other parameters.

Once a batch of liquid waste has been converted to solid waste, thesolid waste is evacuated out of the lower side of the mixing chamber 14,through the outlet valve 22, and into a container (e.g., bag) that maythen be shipped to a solid waste disposal facility. In one embodiment,gravity alone causes the solid waste to exit through the outlet valve22. In another embodiment, an ejection system may pressurize theinternal volume of the mixing chamber 14 via a pressure generator 40(FIG. 2) to push the solid waste out of the valve 22 under force of thepressurized chamber (and gravity, if vertically-oriented). In otherembodiments, an ejection pushing force may be created by a mechanicalapparatus (e.g., a piston, squeegee, etc.) that may be actuated to pushthe solid waste from the mixing chamber 14 (FIGS. 5 and 6) and/or breakthe surface tension at the wall of the mixing chamber 14. In someconstructions, the solidification system includes mechanical means(e.g., a forklift, crane, conveyor, etc.) to receive and transport theejected solid waste.

As shown in FIGS. 5 and 6, an annular piston 42 is illustrated as anexample of a mechanical ejection-assisting apparatus. The annular piston42 may include an elastomeric outer edge that can wipe away residue onthe internal sidewall of the mixing chamber 14. The annular piston 42 ismovable along an axis (e.g., vertical central axis as shown in FIG. 1)of the chamber 14 for wiping away any residue build-up, as illustratedin FIG. 5. The annular shape of the piston 42 allows the SAP powder, theliquid waste, and any created solid waste to freely flow and/or fallthrough an open central portion of the piston 42 (FIG. 6) withoutcreating a significant disruption to the airborne mixing process. Analternate device may include one or more wipers or squeegees arrangeddirectly along the interior wall of the mixing chamber 14, and having alength extended along at least a majority of a length of the mixingchamber 14 below the powder outlet 34, and in some cases along theentire length of a cylindrical wall portion of the mixing chamber 14below the powder outlet 34. The wiper(s) can be rotatable about thecentral axis of the mixing chamber 14 by a driving mechanism (not shown)to release the adhesion between the mixing chamber wall and thesolidified waste so that the waste may be more easily ejected. Thewiper(s) can be oriented parallel to the central axis of the mixingchamber 14 or angled slightly (e.g., less than 30 degrees).

Additionally, the system may include a containerizing (e.g., bagging)system to partially or fully automate the evacuation and disposalprocess.

In operation, liquid waste is accumulated in one or more waste liquidreservoirs 35 until a large enough quantity is collected for a batch ofsolid waste to be created using the waste liquid solidification device10. Alternatively, a quantity of liquid waste can be collected elsewhereand brought to the solidification system. Once enough liquid waste isavailable to run a cycle of the device 10, the device 10 is turned onand the liquid waste is ejected through the liquid outlets 30 as the SAPpowder is discharged from the powder outlet 34. The liquid waste and theSAP powder mix in the air to form the solid waste. The solid waste isheld within the mixing chamber 14 until the batch of solid waste iscompleted. Once the batch is completed, the liquid outlets 30 and thepowder outlet 34 are turned off or closed and the outlet valve 22 isopened to allow for the solid waste to be evacuated (i.e., via thepowered ejection system and/or by gravity). If the ejection system isused, the ejection system is actuated (i.e., the chamber 14 ispressurized or the mechanical ejection system is actuated) to push thesolid waste out of the mixing chamber 14 through the outlet valve 22.The solid waste can be received by any suitable container or conveyancefor handling and optionally shipping purposes. To remove any additionalresidue that may be left on the internal sidewall of the chamber 14, theannular piston 42 or other device may be moved along the chamber wallagain to scrape or wipe away the residue to help keep the mixing chamber14 clean after each batch is processed. The device 10 is then powereddown until the next batch is ready to be created. Alternatively, thewaste liquid solidification device 10 may be automatically actuated by acontrol system that senses when a batch is ready to be started and/orwhen a batch is finished. For example, the device 10 may include asensor (e.g., height/level, weight, flow, timed, etc.) that determinesthe quantity of solid waste held within the chamber 14. In someconstructions, a system may be operated in continuous operation withmultiple mixing chambers 14, rather than a single batch-operated mixingchamber as shown. The total capacity of a plurality of mixing chambers14 can be matched to an incoming flow of waste liquid from a process orsource.

Various features and advantages of the invention are set forth in thefollowing claims.

What is claimed is:
 1. A waste liquid solidification system comprising:a chamber at least partially enclosing a volume; a liquid outletpositioned to spray a liquid into the volume; a powder outlet adjacentthe liquid outlet positioned to discharge a super-absorbent polymerpowder into the volume; and an ejection system for pushing the solidwaste out of the chamber, wherein the ejection system includes apressure generator to pressurize the volume of the chamber to force thesolid waste out of the chamber, wherein the liquid outlet and powderoutlet are configured such that the liquid and the super-absorbentpolymer powder undergo airborne mixing within the volume enclosed by thechamber to create a solid waste, and wherein an outlet from the pressuregenerator is coupled to the chamber separately from the liquid outletand separately from the powder outlet.
 2. The waste liquidsolidification system of claim 1, wherein the ejection system furtherincludes an outlet valve through which the solid waste is forced byoperation of the pressure generator to pressurize the volume of thechamber.
 3. A waste liquid solidification system comprising: a chamberat least partially enclosing a volume; a liquid outlet positioned tospray a liquid into the volume; a powder outlet adjacent the liquidoutlet positioned to discharge a super-absorbent polymer powder into thevolume, wherein the liquid outlet and powder outlet are configured suchthat the liquid and the super-absorbent polymer powder undergo airbornemixing within the volume enclosed by the chamber to create a solidwaste; and an ejection system for pushing the solid waste out of thechamber, wherein the ejection system includes an outlet valve; and amechanical apparatus positioned inside the chamber and operable tophysically engage the solid waste to force the solid waste through theoutlet valve.
 4. The waste liquid solidification system of claim 3,wherein the mechanical apparatus is a piston.
 5. The waste liquidsolidification system of claim 1, wherein evacuation of the solid wasteout of the chamber is automatically controlled by a control system. 6.The waste liquid solidification system of claim 1, further comprising apowder filtration system coupled to the chamber.
 7. The waste liquidsolidification system of claim 6, further comprising a powder reservoircoupled to the powder outlet for supplying the super-absorbent polymerto the volume, wherein the powder reservoir is coupled to the powderfiltration system.
 8. A waste liquid solidification system comprising: achamber at least partially enclosing a volume; a first liquid outletpositioned in the chamber to spray waste liquid into the volume; asecond liquid outlet positioned in the chamber to spray waste liquidinto the volume such that the first and second liquid outlets defineoverlapping spray patterns; a powder outlet coupled with a supply ofsuper-absorbent polymer powder and positioned adjacent the first andsecond liquid outlets to discharge the super-absorbent polymer powderinto the volume; and an ejection system for pushing the solid waste outof the chamber, wherein the ejection system includes a pressuregenerator to pressurize the volume of the chamber to force the solidwaste out of the chamber, wherein the first and second liquid outletsand the powder outlet are configured such that the liquid and thesuper-absorbent polymer powder undergo airborne mixing within the volumeenclosed by the chamber to create a solid waste, and wherein an outletfrom the pressure generator is coupled to the chamber separately fromthe liquid outlet and separately from the powder outlet.
 9. The wasteliquid solidification system of claim 8, wherein the powder outlet islocated below the first and second liquid outlets.
 10. The waste liquidsolidification system of claim 8, wherein the overlapping spray patternsof the first and second liquid outlets encompass an entire cross-sectionof the chamber.
 11. The waste liquid solidification system of claim 8,wherein the overlapping spray patterns of the first and second liquidoutlets are overlapping conical spray patterns.
 12. The waste liquidsolidification system of claim 8, wherein the chamber defines anelongate axial direction having a top end and a bottom end, and whereinthe first liquid outlet, the second liquid outlet, and the powder outletare all positioned nearer the top end than the bottom end.
 13. The wasteliquid solidification system of claim 8, wherein the ejection systemfurther includes an outlet valve through which the solid waste is forcedby operation of the pressure generator to pressurize the volume of thechamber.
 14. The waste liquid solidification system of claim 8, whereinevacuation of the solid waste out of the chamber is automaticallycontrolled by a control system.
 15. The waste liquid solidificationsystem of claim 8, further comprising a powder filtration system coupledto the chamber.
 16. The waste liquid solidification system of claim 15,further comprising a powder reservoir coupled to the powder outlet forsupplying the super-absorbent polymer to the volume, wherein the powderreservoir is coupled to the powder filtration system.